Thanks for all the sympathies. The molds weren't really a factor for this last refit attempt. They were just going to add a layer to the right earpiece which was fine. It probably needs one more layer but at least its a step in the right direction. The left earpiece, however, fit perfectly, but the connector kind of stuck out making it hard to keep behind the ear. I should have just kept it, but I figured I'd want to get it right considering the price of this thing.
So, now the left earpiece which used to fit is now loose and too small in the ear and the connector sticks out much farther. I had to look at my notes to make sure it wasn't my fault, but my description clearly stated that the left ear fit was perfect and I just needed the connector to be a slightly lower profile.
Before sending in for refit:
After:
This is fully inserted. I'll keep you all posted on how things go. I just really hope you CF guys that have been waiting all this time get a good fit upfront. I'd hate to see you have to go through this additional aggravation on top of what you've already been through.